Pump-driven coolant filling device and methods

ABSTRACT

A pump driven coolant filling device and corresponding methods are configured for adding liquid coolant to a coolant circuit for removing heat. The device and methods may be used with liquid coolant circuits on electronic components, or in other industries that utilize liquid coolant. The device includes a base having an integrated pump for circulating coolant to the cooling circuit. A disposable container of coolant may be attached to the base using a threaded connection. The device includes a handle with a switch for controlling operation of the pump in some embodiments. A coolant circuit includes quick connect couplings configured for attachment to corresponding hoses extending from the base. During use, a cooling circuit may continue operation while adding coolant to the cooling circuit using the device.

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the reproduction of the patent document or the patentdisclosure, as it appears in the U.S. Patent and Trademark Office patentfile or records, but otherwise reserves all copyright rights whatsoever.

CROSS-REFERENCES TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH DEVELOPMENT

None.

REFERENCE TO SEQUENCE LISTING OR COMPUTER PROGRAM LISTING APPENDIX

None.

BACKGROUND

The present invention relates to devices and methods for handlingcoolant and more particularly to devices and methods for handling liquidcoolant in liquid-cooled electronics cooling circuits or otherapplications requiring use of liquid coolant.

Many devices in different industries require liquid coolant. Computerand electronic devices such as computer processors and other circuitboard components generate heat. In many applications, thermal effectslimit processing capacity and can lead to undesirable performanceeffects such as slow computing speeds or thermal damage to components.To overcome thermal effects, computing devices commonly include activecooling devices such as fans that blow air over processors or othercircuit components to remove heat. However, conventional air-cooledthermal management solutions are often inadequate to remove excess heatdue to mechanical heat transfer limits of forced air convection.

Active liquid-cooled solutions provide much better heat transfer andcooling performance for computers and electronics as compared toconventional air-cooled solutions. Liquid-cooled systems typicallyinclude a heat exchanger block that may be placed in direct or indirectthermal contact with a circuit component such as a processor. Athermally conductive liquid coolant is circulated through the blockusing a pump, and excess liquid coolant may be contained in a reservoir.In some embodiments, the liquid coolant is passed through a radiatordownstream of the block. Forced air may be blown over the radiator toremove heat from the liquid coolant as the coolant passes through theradiator.

Active liquid-cooled systems typically include a closed-loop liquidcircuit. Over time, liquid coolant in the closed-loop circuit mayevaporate, become contaminated, or excess air pockets may form in thefluid circuit. In such instances, it is necessary to add additionalcoolant to the closed-loop fluid circuit or change the coolant. Thepresent invention relates to devices and methods for adding, removing orchanging liquid coolant in closed-loop active liquid-cooling circuitsfor electronics.

Conventional devices and methods for adding, removing or changingcoolant in a fluid circuit are problematic because they generallyrequire a user to power down the electronics before adding, removing orchanging the coolant fluid. This can be a problem, for example, incoolant circuits for computers or servers where hardware downtime isundesirable. For example, shutting down electronics to enable coolantchanges may lead to cascading effects that require additionalelectronics to be powered down, may cause users to lose connectivity,and may lead to significant economic losses or even damage to hardwareor software in some instances.

Another common problem with conventional devices and methods for adding,removing or changing coolant in a fluid circuit is spillage. Whenadding, removing or changing liquid coolant, fluid must be transferredbetween the closed-loop cooling circuit and an external coolantreservoir, such as a bottle or container of new or used coolant. Theconventional method of attempting to pour the new coolant into areceptacle on the closed-loop circuit using a funnel or spout oftenleads to coolant spillage. In many applications, coolant may causedamage to the electronics or cause a mess that must be cleaned, leadingto more downtime. Additionally, coolant may be hazardous to people insome applications, and human exposure to liquid coolant is undesirable.

What is needed, then are improvements in devices and methods for quicklyand easily filling liquid coolant circuits for electronic devices orother industrial applications.

BRIEF SUMMARY

One aspect of the present disclosure provides a pump-driven coolantfilling device. The device includes a coolant container that screws intoa base with an integrated pump. First and second hoses extend from thebase with quick connect hose fittings on each end to provideinterconnection with a liquid cooling fluid circuit. Once the hoses areconnected to the circuit, the pump may be activated to provide positivepressure driven or negative pressure driven coolant flow to the fluidcircuit.

In some aspects of the disclosure, which may be combined with any otheraspect listed herein unless specified otherwise, a pressure drivencoolant filling device is disclosed. The device includes a container anda base. The base includes an integrated pump, a power supply and ahandle.

In a second aspect of the disclosure, which may be combined with anyother aspect listed herein unless specified otherwise, a method offilling a liquid coolant circuit includes providing a positive ornegative pressure driven coolant filling device with an integrated pump,attaching the device to the circuit, and filling the circuit withcoolant using the pump while the circuit remains on.

The advantages discussed herein may be found in one, or some, andperhaps not all of the aspects disclosed herein. Additional features andadvantages are described herein, and will be apparent from, thefollowing Detailed Description and the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and constitutepart of this specification, illustrate certain preferred aspects of theinvention, and, together with the general description given above andthe detailed description given below, serve to explain the features ofthe invention. In the drawings:

FIG. 1 is a perspective view of an embodiment of a pump driven coolantfilling device with a container, a base and a handle.

FIG. 2 is a partially exploded view of the embodiment of the deviceshown in FIG. 1.

FIG. 3 is a partial cross-sectional perspective view of an embodiment ofa base for a coolant filling device.

FIG. 4 is a partial cross-sectional perspective view of an embodiment ofa base for a coolant filling device.

FIG. 5 is a partial exploded perspective view of an embodiment of a basefor a coolant filling device.

FIG. 6 is a partial exploded perspective view of an embodiment of a basefor a coolant filling device.

FIG. 7 is a partial exploded perspective view of an embodiment of a basefor a coolant filling device.

FIG. 8 is a perspective view of an embodiment of a pump driven coolantfilling device with a container, a base and a handle.

FIG. 9 is a perspective view of an embodiment of a pump driven coolantfilling device with a container, a base and a handle with coolant hoses.

FIG. 10 is a perspective view of an embodiment of a pump driven coolantfilling device with a container, a base and a handle with coolant hoses.

FIG. 11 is a perspective view of an embodiment of a coolant circuitconfigured for use with a pump driven coolant filling device.

FIG. 12 is a perspective view of an embodiment of a pump driven coolantfilling device attached to a coolant circuit.

FIG. 13 is a perspective view of an embodiment of a pump driven coolantfilling device attached to a coolant circuit.

FIG. 14 is a perspective view of an embodiment of a pump driven coolantfilling device and a coolant circuit configured for use with the pumpdriven coolant filling device.

FIG. 15 is a perspective view of an embodiment of a coolant circuitattached to a pump driven coolant filling device.

FIG. 16 is a perspective view of an embodiment of a coolant circuitattached to a pump driven coolant filling device.

DETAILED DESCRIPTION

While the invention is described in connection with certain preferredaspects, it is not intended that the present invention be so limited. Onthe contrary, it is intended to cover all alternatives, modifications,and equivalent arrangements as may be included within the spirit andscope of the invention as defined by the appended claims.

The drawings provide illustrative, non-limiting aspects of the presentinvention setting forth an exemplary packaging and display apparatus andassociated methods. Certain terminology is used herein for convenienceonly and is not to be taken as a limitation on the present invention.While the following describes certain illustrative aspects of thepresent invention, it should be understood, based on this disclosurethat the invention is described by the claims, and is not limited by theaspects described herein.

Referring to FIGS. 1 and 2, an embodiment of a pump-driven coolantfilling device 10 is shown. Device 10 includes a coolant container 12and a base 14. Coolant container 12 may include a disposable bottlepre-filled with coolant in some embodiments. In other embodiments,coolant container 12 includes a re-usable bottle. Container 12 mayinclude any suitable container for storing or housing coolant known inthe art.

Container 12 is mounted into a container socket 20 defined in base 14.Base 14 may be inverted relative to container 12, base 14 and container12 may be threaded together via corresponding threads disposed insidesocket 20 and on the neck of container 12. Once combined, the assemblymay then be rotated such that container is above base, as shown in FIG.1.

A handle 16 is disposed on base 14 to allow a user to easily handle theassembly during use. A flange 30 extends from base 14 in someembodiments, and handle 16 is disposed on flange 30.

During use, liquid coolant contained in container 12 is fed by gravitydownwardly into base 14. Liquid coolant is driven by a pump inside base14 to fill a coolant circuit. Liquid coolant may flow through base 14via first and second filling ports 32, 34. In some embodiments, firstfilling port 32 is an inlet port that receives returning coolant fromthe cooling circuit, and second filling port 34 is an outlet port thatsends coolant to the cooling circuit. In other embodiments, these arereversed.

First and second socket openings 22, 24 are defined in the lower end ofsocket 20. First socket opening 22 is in fluid communication with firstfilling port 32, and second socket opening 24 is in fluid communicationwith second filling port 34. Liquid coolant may travel between eachcorresponding opening and filling port pair. For example, returningcoolant may flow into base 14 though first filling port 32 and flow outof first socket opening 22 back into container 12. Similarly, outgoingcoolant may flow from container 12 down into second socket opening 24and flow out of second filling port 34.

Referring to FIG. 2, in some embodiments, a boss 26 extends upwardlyfrom the lower end of socket 20, and first socket opening 22 is definedthrough boss 26. By positioning first socket opening 22 above the lowerend of socket 20, upward flow of return coolant into container 12 may beimproved to prevent return coolant from immediately entering secondsocket opening 24.

Referring to FIG. 3, an embodiment of a base 14 is shown in a partialcross-sectional view. Base 14 includes an integrated pump assembly 40disposed inside base 14. Pump assembly 40 is housed inside an upper basehousing 64 that also includes socket 20 and first and second fillingports 32, 34. Pump assembly 40 includes a positive or negative pressurepump configured to force coolant flow out of base 14 into a coolingcircuit.

A power supply 50 is also disposed on base 14. Power supply 50 providespower to pump assembly 40. Power supply 50 is disposed in a lower basehousing 66 below pump assembly 40 in some embodiments. Power supply 50includes one or more cells 56 configured to provide power. In someembodiments cells 56 are rechargeable battery cells. In otherembodiments, cells 56 are replaceable batteries. Power supply 50includes any suitable power supply.

In some embodiments, a switch 52 and one or more indicator lights 58 aredisposed on power supply 50. Switch 52 may be configured to controloperation of power supply 50 or pump assembly 40 in some embodiments.Indicator lights 58 are configured to display a signal corresponding toan operational state of the device 10, such as low battery, charged,charging, on, off or any other state of the device.

Referring to FIG. 4, base 14 includes socket 20 having a lower end wall28. In some embodiments, an annular sealing ring 29 extends upwardlyfrom lower end wall 28 in a ring around first and second openings 22,24. Sealing ring 29 includes an inclined outer edge sloping downwardlyto provide an enhanced seal with the inner neck of container 12. Whencontainer 12 is threaded onto base 14, the neck of container 12 is fullyseated into socket 20 such that the container neck engages sealing ring29 at lower end wall 28. Sealing ring 29 prevents leakage of coolant andprovides a seal between base 14 and container 12.

Referring further to FIG. 4, first filling port 32 a extends throughbase 14 and is in fluid communication with first socket opening 22 suchthat liquid coolant travelling into base 14 passes up through firstsocket opening 22 into container 12. Second socket opening 24 ispositioned such that liquid coolant exits container 12 and passes downinto the pump assembly. Coolant passes through second socket opening 24and passes downwardly past impeller pivot 48 in some embodiments. Pumpassembly 40 includes a pump housing 42 located directly below secondsocket opening 24. A circuit board 54 is disposed below pump housing 42in some embodiments, and power supply 50 and cell 56 are disposed belowthe circuit board.

Referring to FIG. 5 and FIG. 6, device 10 includes a base 14 having anupper base housing 64 and a lower base housing 66. A pump assembly 40 isdisposed inside a pump recess 68 defined in the underside of upper basehousing 64. Pump assembly 40 includes an impeller 44 in someembodiments. Impeller 44 fits inside and rotates in an impeller socket46 defined in upper base housing 64. Pump assembly 40 is secured toupper base housing 64 from underneath using one or more pump assemblyfasteners 41 that extend upwardly into corresponding threaded bores 69integrally formed in upper base housing 64 in some embodiments. Pumpassembly 40 is secured to upper base housing 64 forming an integratedpump inside base 14.

Referring to FIGS. 5-7, lower base housing 66 includes a power supply 50and a circuit board 54. Circuit board 54 is secured to lower basehousing 66 using one or more circuit board fasteners 55. Lower basehousing 66 includes pump 50 and handle 16. In some embodiments, a handleswitch 18 is disposed on handle 16 to selectively control operation ofpump 50. Lower base housing 66 is secured to upper base housing 64 usingone or power supply fasteners 51.

As shown in FIG. 7, in some embodiments, base 14 can be described ashaving two sections: a pump 80 and a power supply 50. Pump 80 and powersupply 50 are coupled together to form base 14. Pump 80 includes anupper base housing 64 and an integrated pump assembly 40 having animpeller 44. Power supply 50 includes a lower base housing 66, a batterycell 56, a circuit board 54 and a handle 16.

Referring to FIGS. 8 and 9, in some embodiments, device 10 is configuredfor quick and efficient connection to an electronics cooling circuit.Container 12 is attached to base 14, and then the device 10 may beconnected to a cooling circuit using hoses with quick connect fittings.Device 10 includes a first port hose fitting 72 disposed in first port32, and a second port hose fitting 74 disposed in second port 34. Eachof first and second port fittings 72, 74 are configured to be connectedto a filling hose. For example, as shown in FIG. 9, a first hose 60 isconnected at one end to first port hose fitting 72. A first quickconnect fitting 82 is disposed on the opposite end of first hose 60.Similarly, a second hose 62 is connected at one end to second port hosefitting 74. A second quick connect fitting 84 is disposed on theopposite end of second hose 62. First and second quick connect fittings82, 84 are configured to correspond to like quick connect fittings on acooling circuit. In some embodiments, first quick connect fitting 82 ismale, and second quick connect fitting 84 is female. In otherembodiments, these are reversed.

By providing first and second quick connect fittings 82, 84 as male andfemale, or vice versa, a connecting point on cooling circuit comprisinga male/female joint can be quickly disconnected and easily connected tofirst and second quick connect fittings 82, 84 on device 10. Forexample, as shown in FIGS. 10-13, a coolant circuit 100 includes acoolant block 102 that may be placed in thermal contact with a circuitcomponent. First and second coolant hoses 108 are attached to coolantblock 102 such that coolant may be passed through coolant block 102.Each coolant hose 108 is attached to a radiator 104 for extracting heatfrom the coolant. In some embodiments, radiator 104 includes anintegrated pump 106 configured to circulate coolant through the coolingcircuit 100. In other embodiments, pump 106 may be a separate component.

One of the coolant hoses 108 includes a quick connect joint 110including a male and a female quick connect fitting 112, 114. To add,remove or change coolant in the coolant circuit 100, pump 106 may betemporarily turned off, joint 110 may be separated, and first and secondquick connect fittings 82, 84 on device 10 may be connected to thecorresponding fittings 112, 114 on joint 110, as shown in FIG. 12 andFIG. 13. Once the device 10 is connected to cooling circuit 100, pump 40may be activated on device 10 to circulate coolant 13 from container 12into the cooling circuit 100. This method can be used to fill coolingcircuit 100 if it is empty, to add some coolant to the coolant circuitif the volume is low, or to completely change out the coolant in coolantcircuit 100 with new coolant 13 from container 12.

In other embodiments, the present invention provides a device 10 and acoolant circuit 100 specifically configured for use with device 10without having to power down the cooling circuit. For example, FIGS.14-16 illustrate an embodiment of a device 10 and a cooling circuit 100.Cooling circuit 100 includes a coolant block 102 in thermal contact witha circuit component such as a processor or heat sink. A radiator 104 isconnected to coolant block 102 via a plurality of hoses 108. A pump 106circulates coolant through the radiator 104 and coolant block 102 in aclosed loop. In some embodiments, a reservoir 107 stores excess coolantin the closed-loop system maintaining a steady volume of coolant in thecooling circuit. During use, coolant level in reservoir 107 may becomelow and need to be refilled. The system of the present inventionprovides a solution for filling the coolant in the reservoir 107 withoutturning off circulation of the closed-loop cooling circuit 100.

The system includes a first transfer hose 116 connected to coolantcircuit hose 108 at a T-junction. First transfer hose 116 includes afirst transfer coupling 120 disposed on its distal end. First transfercoupling 120 includes a closed valve when disconnected from othercouplings. Similarly, a second transfer hose 118 is connected to thecoolant circuit at a second location. In some embodiments, secondtransfer hose 118 is connected to the reservoir 107. A second transfercoupling 122 is disposed on the distal end of second transfer hose 118in some embodiments. Second transfer coupling 122 includes a closedvalve when disconnected from other couplings.

During use, device 10 may be connected to coolant circuit 100 by joiningfirst and second quick connect couplings 82, 84 on device 10 to firstand second transfer couplings 120, 122 on cooling circuit 100. Forexample, as shown in FIG. 15, first quick connect coupling 82 on device10 is attached to second transfer coupling 122 on reservoir 107, andsecond quick connect coupling 84 on device 10 is attached to firsttransfer coupling 120 on circuit 100. These may also be reversed inother embodiments. When the device couplings are attached to the circuitcouplings as shown in FIG. 15, each coupling is opened thereby allowingfluid to flow between device 10 and circuit 100. From this position, thepump on device 10 may be activated using handle button 18 to usepositive or negative pressure to force coolant 13 from container 12 intocircuit 100, thereby filling reservoir 107 with additional coolant untilall the air in circuit 100 is evacuated and the closed loop system incircuit 100 is full of coolant. From this configuration, the quickconnect couplings between device 10 and circuit 100 may be detached.This filling method may be performed while coolant is still circulatingthrough circuit 100. Alternatively, circulation in circuit 100 may beturned off during filling.

It should be noted that although the diagrams herein may show a specificorder and composition of method steps, it is understood that the orderof these steps may differ from what is depicted. For example, two ormore steps may be performed concurrently or with partial concurrence.Also, some method steps that are performed as discrete steps may becombined, steps being performed as a combined step may be separated intodiscrete steps, the sequence of certain processes may be reversed orotherwise varied, and the nature or number of discrete processes may bealtered or varied. The order or sequence of any element or apparatus maybe varied or substituted according to alternative aspects. Accordingly,all such modifications are intended to be included within the scope ofthe present disclosure as defined in the appended claims.

The foregoing description of aspects of the invention aspect has beenpresented for purposes of illustration and description. It is notintended to be exhaustive or to limit the disclosure to the precise formdisclosed, and modifications and variations are possible in light of theabove teachings or may be acquired from this disclosure. The aspectswere chosen and described in order to explain the principals of thedisclosure and its practical application to enable one skilled in theart to utilize the various aspects and with various modifications as aresuited to the particular use contemplated. Other substitutions,modifications, changes and omissions may be made in the design,operating conditions and arrangement of the aspects without departingfrom the scope of the present disclosure as expressed in the appendedclaims

What is claimed is:
 1. A coolant filling apparatus, comprising: a basedefining a container socket; a pump disposed on the base opposite thecontainer socket; a first orifice defined in the base inside thecontainer socket, the first orifice in fluid communication with a firstfilling port on the base; a second orifice defined in the base insidethe container socket, the second orifice in fluid communication with asecond filling port on the base through the pump; a power supplydisposed on the base, the power supply connected to the pump andconfigured to provide power to the pump; a switch operable toselectively turn the pump on and off; and a handle attached to the base.2. The apparatus of claim 1, further comprising: a first coolant hosedisposed on the base connected to the first filling port; and a secondcoolant hose disposed on the base connected to the second filling port.3. The apparatus of claim 2, further comprising: a first quick-releasecoupling disposed on the first coolant hose opposite the first fillingport; and a second quick-release coupling disposed on the second coolanthose opposite the second filling port.
 4. The apparatus of claim 3,wherein the pump is a centrifugal pump.
 5. The apparatus of claim 4, theapparatus further comprising: a recess defined in the base; and a pumphousing disposed inside the housing recess.
 6. The apparatus of claim 5,further comprising a circuit board disposed between the power supply andthe pump.
 7. The apparatus of claim 6, wherein the base comprises alower base housing and an upper base housing.
 8. The apparatus of claim7, wherein the pump is disposed in the upper base housing.
 9. Theapparatus of claim 8, wherein the power supply is disposed in the lowerbase housing.
 10. The apparatus of claim 1, further comprising: thecontainer socket including a lower wall; and a boss protruding upwardlyfrom the bottom wall, wherein the first orifice is defined in the boss.11. The apparatus of claim 10, wherein the second orifice is locatedbelow the first orifice.
 12. The apparatus of claim 11, furthercomprising a flange extending from the base.
 13. The apparatus of claim12, wherein the handle extends from the flange in spaced relation to thebase.